Post on 10-Feb-2018
transcript
7/22/2019 Deepak Bhushan
1/46
SUMMER TRAINING REPORT
(BHUSHAN STEEL)
SUBMITTED BY,
DEEPAK SHARMAELECTRICAL AND ELECTRONICS ENGINEERING
(3rd
YEAR 1119421009)
HRCT GROUP OF INSTITUION
Contact : 8826327608
7/22/2019 Deepak Bhushan
2/46
INTRODUCTION
This entire report deals with the study of the various operations
conducted in NCRM (New Cold Rolling Mill) in order to manufactured
the products like cold rolled sheets, galvanized coil etc. during the
entire period we deals with the various processes that are involved in
the manufacturing of the above mentioned products. We visited
departments like HRS, SPM, RGM, GP-1, GP-2 etc. where the various
operations are conducted involved in the production of CR coils,
Galvanized coil. The machines and equipments used are of higher
standard and norms which are imported from the JAPAN, GERMANY
and other countries in order to maintain the accuracy and precision as
well as to produce good quality products. The working environment of
the company is excellent, technicians and workers are highly skilled.
They work hardly to develop standards products and achieving the goals
of the company. Workers are trained by the company to update their
knowledge and skills.
Finally its really a great learning experience for me while working in
the BSL, SAHIBABAD. This training helps me to learn the basics of the
industrial work and other relevant factors which work as the stepping
stone of my professional life. I am thankful to each and every one who is
involved in my work and all the officials, technicians and workers which
help me to learn a fruitful lesson from the working environment of the
BSL, SAHIBABAD.
7/22/2019 Deepak Bhushan
3/46
ACKNOWLEDGEMENT
This summer training is stepping stone towards the beginning of
my professional carrier and its satisfactory has endowed me with
broader horizons of knowledge. This training period is a fruitful
culmination of my concerned affords during my summer
training at Bhushan Steels Ltd. Sahibabad.
I would like to express my thanks to Mr. Mukesh (personal) for
given me an opportunity to a part of this esteemed organization.
I would like to express my deep sense of gratitude to the entire
workers and technicians of various departments. Especially the
HODs of various departments of NCRM for their inspiring
guidance, continuous encouragement and valuable suggestion.
At last but not the least, I would like to thank all personnel of
Bhushan Steels Ltd, who are directly or indirectly involved in
my work for their cooperation and precious help to complete my
training successfully.
7/22/2019 Deepak Bhushan
4/46
COMPANY PROFILE
Bhushan Steel is the largest manufacturer of auto-
grade steel in India and is spending Rs.260 billion to expand its capacity
to 12 million tones annually, from the present installed capacity of
around one million tones.
It was the vision of the founder; Brij Bhushan Singal, that the first stake
was driven into the soil of Sahibabad (Uttar Pradesh) in 1987. His vision
helped BSL overcome several periods of adversity and strive to improve
against all odds.
The company has three manufacturing units in the state of Uttar Pradesh
(Sahibabad Unit), Maharashtra (Khopoli unit), and Orissa Plant
(Meramandali unit) in India and sales network is across many countries.
The company is a source for vivid variety of products such as Cold
Rolled Closed Annealed, Galvanized Coil and Sheet, High Tensile Steel
Strapping, Colour Coated Coils, Galume Sheets and Coils, Hardened &
Tempered Steel Strips, Billets, Sponge Iron, Precision Tubes and Wire
Rod.
As one of the prime movers of the technological revolutions in Indian
Cold Rolled Steel Industry, BSL has emerged as the countrys largestand the only Cold Rolled Steel Plant with an independent line for
manufacturing Cold Rolled Coil and Sheet up to a width of 1700mm, as
well as Galvanized Coil and Sheet up to a width of 1350 mm.
http://en.wikipedia.org/wiki/Steelhttp://en.wikipedia.org/wiki/Tonnehttp://en.wikipedia.org/wiki/Tonnehttp://en.wikipedia.org/wiki/Steel7/22/2019 Deepak Bhushan
5/46
The dynamic reason of awesome and unparalleled growth of BSL is
rapid integration on the Steel value chain; conceivably, it would be its
unwavering focus on acquiring the latest technology and know-how,
also the BSLs commitment to provide its customers with the best
quality products.
Given a vibrant Steel industry dynamics in India, we are on a course to
become a fully Integrated Steel & Power Company with market leading
offerings in value added Steel in Automotive and White Good Segment
with the quality been approved by ISO 9001:2008 & ISO 14001:2004.
7/22/2019 Deepak Bhushan
6/46
Companys Manufacturing Sites
Sahibabad Plant ( Estb. 1987 )BHUSHAN STEEL LIMITED
23, Site IV, Sahibabad Industrial Area,
Distt. Ghaziabad 201010 (U.P.)
INDIA
Products :
Cold Rolled Coil
Cold Rolled Sheet
Galvanized Plane Coil
Galvanised Plane Sheet
Meramandali PlantNarendra Pur
P.O. Shibapur, Meramandali
District - Dhenkanal - 759 121
Products :
Billets
Sponge Iron
Pig Iron
Char
Khopoli Plant ( Estb. 2004 )Village Nifan, Sarvoli, Kharpada Road
Taluka-Khalapur, Near Khopoli
Distt. : Raigad - 410203 (Maharashtra)
INDIA
Products :
Colour Coated Sheets Galume Sheets
Galvanized Sheets
High Tensile Steel Strapping
Hardened & Tempered Steel Strips
CRCA
Precision Tubes
7/22/2019 Deepak Bhushan
7/46
PRINCIPLE
Our mission is to grow our company by providing innovative
strong and high-performance products and solutions to meet our
global customer needs.
Bhushan Steel Ltd formerly known as Bhushan Steel & Strips Ltd. is a
globally renowned one of the leading prominent player in Steel Industry.
Backed by more than two decades, of experience in Steel making,Bhushan Steel is now Indias 3rd largest Secondary Steel Producer
Company with an existing steel production capacity of 2 million tons per
annums (approx.).
It was the vision of the founder; Brij Bhushan Singal, that the first stake
was driven into the soil of Sahibabad (Uttar Pradesh) in 1987. His vision
helped BSL overcome several periods of adversity and strive to improve
against all odds.
The company has three manufacturing units in the state ofUttar Pradesh
(Sahibabad Unit), Maharashtra (Khopoli unit), and Orissa Plant
(Meramandali unit) in India and sales network is across many countries.
The company is a source for vivid variety of products suchas, Galume Sheets and Coils , Hardened & Tempered Steel Strips ,
Billets, Sponge, Iron, Precision Tubes and Wire Rod. As one of the
prime movers of the technological revolutions in
Indian Cold Rolled Steel Industry, BSL has emerged as the countrys
largest and the only Cold Rolled Steel Plant with an independent line for
7/22/2019 Deepak Bhushan
8/46
manufacturing Cold Rolled Coil and Sheet up to a width of 1700mm, as
well as Galvanized Coil and Sheet up to a width of 1350 mm.
Vision of company:-
The vision of evolving into totally Integrated Steel Producer by
committing to achieve the highest standards of Quality through
Cutting-Edge Technology.
The key to Vision is to use rigorous conceptual framework and to
understand how that framework connects to the underlying DNA of
enduring great companies. A well-conceived vision consists of twomajor components
CORE IDEOLOGY and an ENVISIONED FUTURE. A
good vision builds on the interplay between these two complementary
Yin-and-Yang forces; it defines What we stand for and Why we
exist that does not change the Core Ideology and sets forthWhat we
aspire to become, to achieve, to create that willrequire significant
change and progress to attainthe Envisioned Future.
7/22/2019 Deepak Bhushan
9/46
Our Vision
About Culture: -To make it a place where all the people can thriveliving, learning and working in a clean, safe and healthy
environment.
About Values:-To corporate values as the rules or guidelines by
which a corporation exhorts its members to behave consistently
with its order, security and growth.
About People: - See the good in people and try to develop those
qualities i.e. preparation and grooming of the next generation of
the young thinkers.
About Customers: - Sell good merchandise at reasonable price;treat our customer like we would treat our friends and the business
will take care of itself. Bhushan Steels endeavor is to attain the
highest level of CustomerSatisfaction.
About Products: - We should always be the pioneers with our
productsout front leading the market.
7/22/2019 Deepak Bhushan
10/46
Policies
INTEGRATED QUALITY, ENVIRONMENT, OCCUPATIONAL
HEALTH & SAFETY MANAGEMENT SYSTEM POLICY
Bhushan Steel Ltd. commits to produce cold rolled and galvanized steel
sheets of world class quality in a safe, healthy and clean environment by
involving employees with continual improvements in system
implementation, technological advancement, operational integration,prevention of pollution & hazards maintaining
Legal compliance and satisfying needs & expectations of
Customers:-
For Environmental Management System we have ISO 14001:2004
Certification
For Quality System we have ISO/TS 16949:2002 Certification
For Safety Management System we have OHSAS 18001:2007
Certification
7/22/2019 Deepak Bhushan
11/46
Current capacity of Sahibabad Plant
Facility Capacity (TPA)
H.R. Slitting Line(2) 2,40,000
Pickling Line (2) 9,00,000
6 HiHitachi Reversible Mill 3,50,000
6 HiFlat+ Narrow Reversible Mill 1,25,000
Electrolytic Cleaning Line 3,50,000
Annealing Line Batch Type (Hydrogen) 2,76,000
Laddle Refining Furnaces 3,60,000
(Storage
Capacity)
30 Bases
Kathabar 180 T
Roll Grinding Machine 2 Machines
Roll Texturing Machine (EDT Machine) -
4 Skin Pass Cum Tension Leveling Line 3,30,000
C.R. Slitters
Cut-to- Length
3,00,000
Galvanizing Line 2,25,000
7/22/2019 Deepak Bhushan
12/46
Finished Products at Sahibabad Plant
Cold Rolled Coil
Cold Rolled SheetGalvanised Plane Coil
Galvanised Plane Sheet
Galvanised Corrugated Sheet
Process Layout
7/22/2019 Deepak Bhushan
13/46
Various Departments and their HODs
Department HOD
Safety Mr. Sudhir Kumar
HRS/Pickling Mr. AK Dixit
Hitachi-Mill Mr. Neeraj Sharma
ECL Mr. SK Sood
Annealing Mr. Neeraj Gupta
Skin Pass Mill Mr. Satyaveer
Finishing Mr. AK Kansal
Colour Coating Mr. Suresh Sharma
Quality NCRM Mr. AK Mukherjee
GP-1 Mr. RC Singh
Utility Mr. AK Gupta
Electrical Maintenance Mr. KK Mathur
Quality System Mr. Deepak Aggarwal
7/22/2019 Deepak Bhushan
14/46
SAFETY
The service provider and his men should comply with personal
protection equipment (PPE) requirement decided by the organizationsafety department like Cut Resistance, HandGloves, Safety Helmets
and safety Helmets and SafetyShoes.
All the PPESmust be worn while working on job.
The service provider should be competent enough to supervise his
men.
GENERAL SAFETY GUIDELINES
Service Provider must not operate any equipment in manual mode
without permission from authorized engineer.
Service Provider must not go to any equipment while moving.
No person is allowed to stand on coil car / slitting line.
No By-passing of interlocks and no pre assumptions for any
equipment operation.
Use Proper PPES& Safety platform while packing.
Ensure that, fingers should be away from strapping procedure and
while working with tensioner.
Service Provider trained operator should handle consumables for
packing of Coils.
7/22/2019 Deepak Bhushan
15/46
Operators should be away from under crane, while crane carrying the
Coil/ Plates to packing saddle/ packing area.
Service Provider must remove the waste consumables immediately
Specified scrap bin and keep the area neat &clean.
Service Provider must keep only good quality wooden logs for
packing.
Service Provider must always wear sufficient PPEs inside the plants.
Service Provider must keep safe distance to the coils & packs while
packing.
Service Provider must not modify any tools or equipments.
Service Provider must not touch any movable parts.
Service Provider must riggers must be alert while pack stackingprocedure in yard.
Extra care to taken while packing with fork lifter. The signal to be
given to fork lifter driver by standing at least one meter away from pack.
Service Provider must keep the packs stack height maximum 6 feet
and must not stack the packs more than 6 feet height.
Rigger must ensure as coil properly gripped in sling-gofer/c-hook
than after give the signal to the crane operator.
Service Provider must not put wooden blocks for packing while the
crane is moving with load.
7/22/2019 Deepak Bhushan
16/46
Pickling line
Mainly pickling of coil is used to remove corrosion or rust, which is
produced on coil surface due to interaction of coil surface with air and
moisture. This may form an oxide layer on coil surface, which may
cause of reduction of metal and improper surface finish.
Pickling in a solution of hydrochloric or sulphuric acid. The acid
dissolute the oxide scales from the strip surface according to the
reaction:
Fe2O3 + 6HCl = 2FeCl3 + 3H2O.
Rinsing and passivation of the strip. At this stage the acid residuals are
washed by water from the strip.
Passivation film is formed on the strip surface providing corrosion
protection.
Drying.
Edge Trimming.
Oiling.
Recoiling.
7/22/2019 Deepak Bhushan
17/46
Specification:
Type of Line PushPull
Material Hot Rolled M.S.
Strip Thickness 6.0 mm
Strip Width 1700 mm
Coil O.D. 2000 mm
Coil Wt. 30 MT.
Pickling Cascade with 2/3/4 tanks
Rinse Multi stage cascade hot rinse
Pickling Medium HCL
7/22/2019 Deepak Bhushan
18/46
Additional Features
Online Side Trimming.
Oiling.
Roll Bending.
Quick Work Roll Change.
These pickling lines can process strips varying from 1.0mm to 12.0mm
thick and 200mm to 2000mm wide.
Picking lines process one coil at a time, therefore eliminating the need
for joining strips. This process allows immense flexibility of operation &
also ensures easy operation and maintenance. As accumulators are notrequired in these lines, thus making them cost effective in nature. These
pickling lines are capable of producing between 200,000 to 1,000,000
Tons per annum.
7/22/2019 Deepak Bhushan
19/46
Hot Rolled Slitter
This process is performed for removing unwanted material, giving
fatness, side cutting to get desired shape or width, remove side bending,
defects like notches etc.
Various process involved are-
Loading of coil
Feeding of coil
Setting of cutter
Trimming
Recoiling
Removal of coil
Stepping & labeling of output material
Storage of output material
7/22/2019 Deepak Bhushan
20/46
Slitting Lines
Slitting Lines, Slitting Lines have been successfully put into
operation in well-known production plants & service centers. These
lines have the capability to meet client's demand for minimum burr, no
damage to the surface, high production capacity etc., to the fullest. The
high automation level of the lines reduces the need for operator
attendance and ensures economy of operation.
Characteristic Features:
High automation level to achieve high economic efficiency
Minimum burr on strip edges due to high running accuracy of knife
arbors
No manual interferences required as the edge scrap baller is pitmounted
Additional Features :
Quick Slitter Head Change with Standby Slitter Head.
Dual speed lines to cover wider range of thickness.
7/22/2019 Deepak Bhushan
21/46
H.R.Slitter
Specification:
a) Type of Line Loop / Pull Thru'.b) Material Hot Rolled M.S.
c) Strip Thickness 10.0 mm.
d) Strip Width 2000 mm.
e) Coil O.D. 2000 mm.
f) Coil Weight. 3MT.
g) Line Speed 200 mpm.
Additional Features:
Quick Slitter Head Change with Standby Slitter Head.
C.R.Slitter
Specification:
1. Type of Line Single / Double Loop.
2. Material CR FH / CRCA / GALVANIZED / COLOUR
COATED.
3. Strip Thickness 3.0 mm.
4. Strip Width 1650 mm.
5. Coil O.D. 2000 mm.
6. Coil Wt. 3MT.
7. Line Speed 250 mpm.
7/22/2019 Deepak Bhushan
22/46
Galvanizing Line
We offer hot-dip galvanizing lines. The lines manufactured by us are
furnace type, heat to coat type or wet flux type. Efficient air-knivescontrol the thickness of coating with great precision, either through
manual settings or through automatic coat control systems. The
materials can be pickled hot rolled steel, cold-rolled steel of CQ, DQ
quality & full hard in nature.
Specification:
Additional Features:
On Line Skin Passing.
On Line Tension Leveling.
Double Recoiler on Exit Side
7/22/2019 Deepak Bhushan
23/46
7/22/2019 Deepak Bhushan
24/46
7/22/2019 Deepak Bhushan
25/46
7/22/2019 Deepak Bhushan
26/46
GP1
A. WORK INSTRUCTION FOR ENTRY SECTIONAPPROVED PROCESS APPROVED MACHINERY
Coil loading Coil car & uncoiler
Welding unit
B.LINE SPECIFICATION
MONITORING OF PROCESS PARAMETERS
SPEED
Entry speed 1520mpm
TENSION
Entry (POR) 56560mpm
Entry accumulator 105 TO 1050 Kg
POSITION
Entry accumulator190% Filled
POR initial data 500mm600mm
C.OLD ROLED MATERIAL SPECIFICATION
Hardness of material 45100 HRB
Thickness of strip0.172.2mm Width5001280 mm
Weight0.5MT (min.), 22MT (max.)
Initial diameter of coil 500 mm600mm
7/22/2019 Deepak Bhushan
27/46
D. COLD ROLLED MATERIAL INSPECTION Preferably coil should be free from edge cut & saw edges.
Shape & surface finish of the cold rolled coil is inspected by entryoperator & also enters the same in log book.
E. INTRODUCTION FOR ENTRY SETUP Made entry section ready by pressing switch.
Make accumulator tension on by pressing switch.
Make POR tension on by pressing switch. Make entry start by pressing switches.
F. COIL LOADING
Coil is loaded with the help of coil car.
7/22/2019 Deepak Bhushan
28/46
Electrolytic Cleaning Line
Utilizing a performance enhanced, low temperature, high volume,
updraft re-circulating hot air design, the Electrolytic cleaning line isideal for refreshing steel products and other metallic mater. The
Electrolytic cleaning lines are the ideal wet cleaning complement for
advanced Electrolytic components.
Specification:
Additional Features: On line trimming
7/22/2019 Deepak Bhushan
29/46
Electrolytic Cleaning is required in case material rolled with high
percentage of oil while reduction in mills goes for annealing in furnace.
Oil free base material is essential for the production of bright and
corrosion resistant steel. Sodium Orthosilicate is used as cleaning agent
in ECL.
Tension is given according to thickness, width based on customer
requirement.
The installed production capacity of the line is 86102 MT/Annum.
7/22/2019 Deepak Bhushan
30/46
ROLL GRINDING MACHINE:-
It is a three rolled grinding machine.
It is basically used to treat the roll which are used continuously in certain
machines like Hitachi Mill , Pickling line etc.
In this machine we use two categories of rolls namely
Intermediate Rolls
Back Up Roll
PROCESS FLOW DIAGRAM FOR RGM
1 Pre inspection of roll:
In this step the rolls are inspected in order to identify their defects.
2 Loading of roll:In this step the rolls which are found defected ones are load with
the help of coil car.
3Selection of Machine Control Program (MCP):
In this step particular computer operated programs are selected to
operate on the loaded roll.
4Rough Cutting of Roll:
In this step rough cutting of rolls are done with the help of shear.
A shear cutting oil is used in order to control friction and to
reduce the temperature develop on the surface.
7/22/2019 Deepak Bhushan
31/46
5Inspection of roll:
This step is performed to find the any defects or extra material
attached to the surface of the rolls.
If any defect is found then the roll is sent for the cutting operationto remove those defects.
6 Finishing of rolls:
After the inspection process finishing operation is done on the
roll.
Now the rolls are ready to use for their operation in the machines
like Hitachi Mills, SPM etc.
7Texturing (only for W/R) :
In this process Electric discharge is used in order to provide the
desired Roughness to the rolls so that they perform their function
satisfactorily
If this operation is not conducted then roll will not perform its
work properly and hence the product formed will not be of good
accuracy and precision.
8 Unloading, storage & Transport:
Finally the defect free roll is obtained .Now it is ready for reuse.
Now it is unloaded with the help of coil car and sent back to the
different mills for use.
DEFECTS OF ROLLS Roll Bite
Pinchers
Chattering Marks
Floppers (Pinching Marks)
7/22/2019 Deepak Bhushan
32/46
Annealing Line
Annealing Line: The demand for better annealed stainless steel has
increased. Annealing is a heat-treating process conducted undercontrolled-atmosphere furnace to minimize oxidation, so that the product
surface remains clean. It is very common for continuous annealing of
strip products and stainless steels.
Type of Line Horizontal Tight Line
Material Stainless Steel.
Strip Thickness 1.5 MM.
Strip Width 660 MM.Coil O.D 1650 MM.
Coil Wt. 10 T
Line Speed 30 MPM
Additional Features: Tension control in closed loop.
Annealing For Stainless Steel:-
The heat treatment has to be specific in annealing and pickling line to
find the best compromise between strength and ductility without
neglecting the surface finish.
Annealing and pickling lines (APL's) are used for the treatment of hot
rolled (HR) and cold rolled (CR) stainless steel strips.
HR Austenitic & CR strip is annealed and pickled continuously in an
APL and HR ferric strip is only pickled. Lines for HR & CR, as well as
dedicated APL's process the majority of the stainless steel production.
7/22/2019 Deepak Bhushan
33/46
Annealing at a temperature 1100-1300F (600-700C) in a controlled
reducing atmosphere (commonly a mixture of Hydrogen and Nitrogen)
preventing oxidation of the steel surface. Annealing results in
recrystallization of the steel Grain structure and in stress relief. There are
two alternatives of annealing process continuous annealing line andbatch annealing furnace. In the continuous annealing line (see the picture
below) steel strip passes annealing furnace at a controlled speed. In the
batch process steel strip coils are stacked on top of each other in the bell
type furnace. Batch annealing allows to achieve lower hardness and
higher ductility of the steel than in alternative continuous annealing.
Batch Annealing Furnace
The process of annealing of cold rolled coil is carried out to obtain the
desired properties in the finished coils. For this, the material is heated to
predetermined temperature in a protective atmosphere and soaked for a
specified time before it is put to room temperature. Optimum condition
with annealing atmosphere, annealing cycle, sealing and purging have to
be maintained to obtain a finished product with bright surface, desired
micro structure and uniform properties throughout the coil.
HSD is used for heating the surface. Nitrogen is purged inside the inner
cover. Nitrogen is obtained from PSA Unit. The installed production
capacity of
the line is 75881 MT/annum.
7/22/2019 Deepak Bhushan
34/46
Rewind cum Trimming Line
Built from the basic elements of the compact trimming line, the modularline mechanically trims the edges through chip removal process. Any
desired dimension ispossible depending on strip width and thickness.
The number of tools operatingsimultaneously is variable. It is frequently
used in the welded tube production.
Additional Features: Two - speed arrangement.
7/22/2019 Deepak Bhushan
35/46
Coil build-up Lines
The coil build-up lines are used for side-trimming of the strips and alsoprovide the coils with leader strips that can be reused for optimization of
the yield. With suitable inclusion of welder, these lines can be used for
building up bigger coils from small coils, with roll-able weld.
1. LOADING OF COIL
Cold Rolled (CR),GP Coil or skin passed coil is loaded
on the coil car/turnstile by crane.
2. FEEDING OF COIL
o The coil is fed from uncoiler using Peeler Table.
o The coils outer 2/3 damaged wraps are cut by shear.
3. SETTING OF SLITTER & SLITTING OF COIL
o
Proper set of cutters and rubbers to be used for setting of slitter.o During slitting the operator must check the back tension &
regulate it properly.
o The pneumatic pressure on pressure pad should in between 2- 2.5
bar.
4. CLEANING OF MACHINE
All rotating parts & rolls should be cleaned regularly.
Line should be cleaned regularly after processing of
approx. 80100MT of material.
7/22/2019 Deepak Bhushan
36/46
5. RECOILING &UNLOADING.
6. PACKING OF COIL
COLD ROLLED SLITTER
MINIMUM MAXIMUM
Speed 400 mpm
Coil width II400 mm1700 mm
Strip thickness 0.10mm3mmCoil weight 3 MT
7/22/2019 Deepak Bhushan
37/46
COLD ROLLING MILL:-
There are two types of Cold Rolling Mills operates, which are 6 Hi ColdRolling Mill and 4 Hi Cold Rolling Mill.
Pickled Hot Rolled Coils of higher gauges are reduced to required
thinner gauges by passing through the Mills. In 6 Hi Mill the reduction
achieved is up to 0.13mm ultrathin gauge whereas 4 Hi can reduce the
thickness up to 0.25mm. The computer controlled rolling process
ensures closure thickness tolerances and perfectly flat strips.
The installed production capacity of 6 Hi Mill is 23,856 MT/annum and4 Hi Mill is 43,502 MT per annum.
Cold Rolling Mills our cold rolling mills are specifically designed for
breakdown rolling of ferrous/ non-ferrous sheet & strip. The rolls are
manufactured from alloy steel, having high hardness of about 60-62
HRC. The produced steel is considered to be "full hard". Cold-rolled
steel products begin as hot rolled pickled and oiled coils. These coils are
"cold-reduced" by passing them through a cold reduction process on areversing mill under high tension and pressure.
Mill Specification:
7/22/2019 Deepak Bhushan
38/46
Additional Features:
Hydraulic Automatic Gauge Control.
Thickness Gauges.
Roll Bending.
Quick Work Roll Change.
7/22/2019 Deepak Bhushan
39/46
Skin Pass Mill:-
Skin Pass Mill These skin pass mills are specifically designed for
manufacturing sheet / strip of medium hardness or to provide finish pass.
The Rolls are made of alloy steel & have high hardness, which is
generally up to 65 HRC or more. For increasing demands with respect to
strip flatness, elongation and roughness, especially for hard material
grades, skin-pass mill is an ideal solution due to higher rolling forces
and torques that can be achieved in this case.
7/22/2019 Deepak Bhushan
40/46
Temper rolling (skin pass rolling) - final cold rolling operation with
low thickness reduction conducted in order to impart to the steel
required levels of hardness, evenness and surface finish. Four-high
rolling mill is used for tempering.
Most of annealed low carbon steel strips are tempered since they are too
soft (HV
7/22/2019 Deepak Bhushan
41/46
Quality control:
BSL have fully fledged laboratory with test equipments such as
Emission spectroscope for the chemical analysis, computerized
Universal testing machine with stress-straingraph for tension tests,
surface finish tester, Hardness testers using both Vickers and
Rockwell scales, LFQ testing machine, Cupping tester, on line
Radiometric and off line chemical lab for coating mass, salt spraytester for corrosionresistance, and Humidity chamber.
o ForEnvironmental Management System we have ISO
14001:2004 Certification
o ForQuality System we have ISO/TS 16949:2002
Certification
o
ForSafety Management System we have OHSAS18001:2007 Certification
The main concern of the company is to
Maintain the international norms of steel industry to develop the
accurate and precise products by preserving the environmental
balance and constituting an ecofriendly environment by utilizingmodern and advanced techniques available in the market.
7/22/2019 Deepak Bhushan
42/46
HARDNESS TEST: -
Hardness is a surface property.
It is defined as the resistance of a material against permanent
deformation of the surface in the form of scratch, cutting,
indentation, or mechanical wear.
BRINELL HARDNESS TEST:-
This test is conducted for the specimen with range 0 to 10.
In this test hardened steel ball is used as an Indenter. Indenter is
used to introduce indentation on the surface.
This machine is called push-pull button type machine because
the indenting load is applied by pushing a button.
Before conducting the test, the surface of specimen is made free
from oil, grease, dust and dirt.
FORMULA:-
BHN = Indenting load in (kgf)/spherical surface area of indentationin (mm2)
7/22/2019 Deepak Bhushan
43/46
VICKERS HARDNESS TEST
This test is similar to Brinells test but uses a different type of
Indenter.
A Square based Pyramid Indenter of cone angle (=136 degree
Celsius) between opposite faces of pyramid is used.
The applied loads may be 5, 10, 30, 50, 50, 100 or 120 kgf.
FORMULA:-
VICKERS HARDNESS = 1.8544P/d2 (for cone angle = 136)
This test is performed for smaller cross sections, very hard
materials, polished and nitride surfaces, and very thin test pieces.
TENSILE TEST
This test is performed on machines such as given below.
1. Hounsfield Tensometer,
2. Universal Testing Machine(UTM)
3. Instron or other Material Testing Machine (MTS).
4. Universal Testing Machine (UTM)
7/22/2019 Deepak Bhushan
44/46
The UTM have large load capacity, generally ranging from 0-4
Tonne. Materials with large sections and high tensile strength
such as steel bars are tested on them.
Tensometer is generally mechanically operated while UTMs are
hydraulically operated. They can be controlled by computers orcan be operated manually.
R & D department :
For continuous bench marking of our product quality, we keep
carrying out testing from outside laboratories. This has resulted incontinuous upgrading of the process parameters confirming to any
international standards. Further, we have online backup SGS
inspection for all test parameters up to the point of dispatch. We
are IS0 900l certified. Our products are accompanied with mill
test certificates and packing lists.
Following tests are conducted in order to maintain the accuracy
and precision and standardization of the products manufactured in
the plants according to international norms of the steel market.
7/22/2019 Deepak Bhushan
45/46
Conclusion
Cold Rolling Mill Complex (CRM)
The various processing units involved in the CRM complex and theirfunctions are given below:
The waste liquor from pickling line, recoiling line are treated in effluent
treatment plant ensuring pollution free environment. The acid
regeneration plant ensures regeneration of hydrochloric acid from waste
pickled liquor for reuse in pickling line.
Continuous Pickling Line (Cpl):
The HR Coil, which is the basic raw material, is passed through CPL toremove the oxides or scales from strip surface to enable further
reduction of thickness to desired level in Cold Rolling Mills. This
processing is required since rust is formed on the surface of the coils at
room temperature whereas scales are formed at high temperature during
rolling in Hot Strip Mill.
Cold Rolling Mill
Pickled Hot Rolled Coils of higher gauges are reduced to required
thinner gauges by passing through the Mills. In 6 Hi Mill the reductionachieved is up to 0.13mm ultra-thin gauges whereas 4 Hi can reduce the
thickness up to 0.25mm. The computer controlled rolling process
ensures closure thickness tolerances and perfectly flat strips.
Electrolytic Cleaning LineElectrolytic Cleaning is required in case material rolled with high
percentage of oil while reduction in mills goes for annealing in furnace.
Oil free base material is essential for the production of bright andcorrosion resistant steel. Sodium Orthosilicate is used as cleaning agent
in ECL. Tension is given according to thickness, width based on
customer requirement.
7/22/2019 Deepak Bhushan
46/46
Annealing Furnace
The process of annealing of cold rolled coil is carried out to obtain the
desired properties in the finished coils. For this, the material is heated to
predetermined temperature in a protective atmosphere and soaked for a
specified time before it is put to room temperature. Optimum conditionwith annealing atmosphere, annealing cycle, sealing and purging have to
be maintained to obtain a finished product with bright surface, desired
micro structure and uniform properties throughout the coil. HSD (High
Speed Diesel) is used for heating the surface. Nitrogen is purged inside
the inner cover.
Skin Pass Mill
In this process the cold rolled annealed strips are given a desired surfacefinish. It improves the flatness and suppresses the yield point elongation.
Anti-rust oil is used on strip surface as protection from rust.
Bibliography
1.
Wikipediawww.en.wikipedia.orgwikiBhushanSteel
2.Bhushan Steel Official Website
www.bhushansteel.com/
http://www.bhushansteel.com/http://www.bhushansteel.com/